CASE STUDY · COMMERCIAL
Metal Lockers for Thinventory (ByBox)
JC Metalworks recreated Thinventory’s existing locker design from physical samples and standardised components to support consistent, repeat production.
- Security Details: Sealed rivets, security screws
- Component Standardisation: Simplified repeat fabrication
- Design Adjustments: Improved sheet material use
- Storage and Despatch: Inventory support before despatch
INDUSTRY
Inventory Management
PRODUCTS
Metal Inventory Lockers
SERVICES
Reverse Engineering & Fabrication
OUTCOME
8,000+ Lockers Delivered
Background
Recreating a Locker Design for Repeat Production
Thinventory, previously known as ByBox, provides inventory management solutions for field service companies. Its inventory lockers help customers maintain visibility and control of stock in real time.
For this project, JC Metalworks was asked to reproduce Thinventory locker designs at volume. The customer supplied sample lockers, but engineering drawings were not available to define the complete construction. The team therefore needed to establish the dimensions, materials and build details from the physical samples before moving into repeat production.
The work combined sample-led reverse engineering with practical adjustments to component design and standardisation. Storage support was also part of the original project arrangement, helping manage locker inventory ahead of despatch.
Challenge
Reproduce Existing Lockers Without Engineering Drawings
The sample lockers showed the intended product, but the project did not come with engineering drawings. JC Metalworks needed to understand how the lockers were assembled, work out the dimensions of the individual parts and identify the materials and fixing details used in the original construction.
The volume of lockers required and the need to respond to demanding delivery timelines made an efficient, repeatable production approach important. The team had to translate the samples into practical fabrication information without losing the construction details needed for the finished locker.
Engineering From Physical Samples
Establish overall dimensions and component details, including shelves, hinges and locks.
Material and Construction Assessment
Identify the steel types used across the locker body, doors and internal components.
Security-Related Details
Understand the fixing approach, including sealed external rivets and security screws in place of external screws.
Production Repeatability
Standardise components where possible and make minor design adjustments to support fabrication and sheet-material utilisation.
Solution
How JC Metalworks Responded
We reverse-engineered the customer sample lockers that were supplied to us. Our design engineers worked closely to understand what was required. We conducted a comprehensive analysis of the customer-provided locker samples. This process involved meticulous examination of the lockers’ construction, including:
Material Composition
Determining the specific types of steel used for the locker body, doors, and internal components. Lockers are constructed primarily using galvanised and Zintec materials.
Fabrication Techniques
Analysing the welding methods, bending processes, and assembly techniques employed in the manufacturing of the lockers.
Dimensional Measurements
Precisely measuring the overall dimensions, as well as the dimensions of individual components such as shelves, hinges, and locks.
Security Features
All fixings used in Thinventory lockers are made of stainless steel or structural steel to reinforce their security. External rivets are sealed, while external screws are replaced with security screws to deter tampering.
Standardisation and Efficiency
JC Metalworks standardised locker components and made minor design adjustments to suit fabrication processes and improve sheet material use, streamlining production and creating a flexible foundation for future locker designs.
Storage and Dispatch
To streamline inventory management and expedite delivery, JC Metalworks offers a storage facility to Thinventory. Our central location provides a significant advantage in minimising transit times and reducing handling.
RESULTS
A Repeatable Approach to High-Volume Locker Supply
The project brought together reverse engineering, materials assessment, attention to security-related fixings and component standardisation. Instead of relying on drawings that had not been supplied, the team used the customer’s physical samples to establish the locker construction and inform the production approach.
More than 8,000 lockers were delivered, demonstrating JC Metalworks’ ability to translate the existing design into a repeatable production process. Standardised components and consistent construction details helped maintain the design across production runs.
8,000+ lockers manufactured and delivered.
Demanding client delivery timelines met.
Design refinements improved sheet material utilisation.
Sealed rivets and security screws helped deter tampering.
Here at Thinventory, we do work with a lot of suppliers, JC Metalworks are by far one of the best that we work with due to their flexibility and constant willingness to go above and beyond.
– Kevin Barrs, Service Product Manager.
METAL LOCKERS FOR THINVENTORY (BYBOX)
A project summary for procurement, engineering and product teams working on locker systems and recurring supply programmes.
Includes project background, sample-led reverse engineering, material and construction details, standardisation for repeat production, and storage support.
